Magnum fitness UB300 User manual

Maintenance Manual for
UB300 and UB300H
Versions 1.1 – 1.3
Magnum Fitness Systems
2201 12th Ave
South Milwaukee, WI 53172
800-372-0554
www.MagnumFitness.com
Updated 2-2011

1
Table of Contents
Using the set-up mode 2
Flowchart 1.1 No Resistance / No power to upper console 3
Flowchart 1.2 Membrane switches not functioning 4
Electronic connections and LED locations 5
Electronics part numbers 6
Seat assembly part numbers 7
External component part numbers 8
Head assembly part numbers 9
Handle part numbers 10
Tranny part numbers and diagrams 11-13

2
CUSTOMIZING YOUR UB300 USING THE SET UP MODE
Follow the steps below to enter the set up mode, there is a brief description of the function of each setting and how to customize
it for your needs.
-Start cranking the unit to display the welcome screen (you will need to continue to crank to keep the board lit during the
process)
-press and hold both the RESET and the ENTER keys until the display changes to read the first setting below
-use the RESISTANCE HIGHER and RESISTANCE LOWER keys to adjust the settings in each parameter choice.
When you are satisfied with a particular setting use the ENTER key and the new setting will be used and will move to
the next setting, in other words…
-ENTER moves you to the next setting
-HIGHER / LOWER changes the choices in a particular setting
Setting Default Summary and features
Version xxx This is the current software version that is in use, this setting is for
information only
Units US Use the resistance higher/lower key to select between US and Metric
Reduct Ratio 5.05 Used to determine the correct ratio for rpms, do not adjust
Mode Medical Use the resistance higher/lower key to select between Fitness, Medical,
Trainer
Fitness: basic mode of operation
Medical: same as fitness but will allow the user to change resistance levels
in .1 increments and will display METS in the scrolling screen
Trainer: same as Medical but includes four additional interval training
programs
Unit type Upper Lower is used for everything but the UBE series of equipment where Upper
should be selected using the resistance higher key
Lvl 20 Brake 400 this is the actual resistance that the brake will exert when the display reads
level 20 resistance, the range is 0-1023, the higher the number the greater
the resistance
Start Level 0.0 this is the starting level that comes up automatically when you select
quickstart, from here you can manually increase or decrease the resistance
throughout the workout
ABS Max Brake 750 This is the ABSolute maximum braking that the program is allowed to
exert during any given program, range is 0-1023
Heart Rate beat to beat do not adjust
HR type No Contact selectable between Use Contact and No Contact, if your unit has contact
HR select Use contact, if you do not have the contact HR option select No
Contact
Acceleration 20 this is an arbitrary number to how fast the program reacts to the resistance
changes
* example: at default settings it takes 5 seconds to feel the maximum
resistance change when going from 0 to 10 resistance, if we double the
acceleration to 40 it should take half the time or 2.5 seconds
Comm Disabled Use the higher / lower resistance key to select between the different options
UHRS xxx this is the amount of hours used since this number was last reset, to reset
press CLEAR
THRS xxx this is the amount of hours Total on the bike and is not resettable.
Once you hit ENTER this last time it should go back to the welcome screen and all your changes will be saved.

3
Flowchart 1.1 No Resistance / No Power to display
no no
yes
yes
yes
n o
yes no
no
yes
no yes
no
yes
no
no
yes
no yes
no
Remove plastic
rivets and (3)
screws on main
plastic covers to
reveal the interior
of the unit
Pedal the unit, press
START, then the resistance
^ to level 10.0, did the
buttons work?
*START HERE*
Does the board light
up when the unit is
"pedaled?"
Is the generator
spinning when
the unit is being
"pedaled?"
Check LED DC
BUS on the lower
board. Is it lit?
Are the belts
still on all the
pulleys? See
head assembly
picture.
Replace telco
communication
cables between
upper and lower
boards. Fixed?
Replace upper
console.
Track the belts
Check for voltage
DIRECTLY on 3
pins on generator
while spinning, any
voltage?
Replace or fix
continuity on 3
pin brake wire.
Replace
generator brake.
Check clutch in
part (14) and (16)
in tranny 1,2,3
See flowchart 1.2 to
diagnose membrane
problem.
Remove plastic
rivets and (3)
screws on main
plastic covers to
reveal the interior
of the unit
Pedal the unit, press START,
then the resistance ^ to level
10.0, check LED BRK IN on
power supply board, is it lit?
Replace telco
communication
cables, do you
have resistance?
Check LED BRK
OUT on power
supply board, is
it lit?
Replace lower
power supply
board.
Replace upper
console.
Check
continuity
of 2 pin
brake
wire, is it
good?
Replace 2
pin wire.
Replace
generator.

4
Flowchart 1.2 Membrane Switches not functioning
Figure 2.1
D
A
B
C
833-124 833-132 833-122 833-124
Right Stop/Reset Lower keypad Upper keypad Right Stop/Reset
yes
no
no
yes
no
yes
no
yes
no
Remove screws to
reveal back of
upper console
board.
Replace the
keypad that
does NOT
function.
START HERE
Do any of the keys
function while the
board is lit up?
(beep noise)
Unplug B,C,D in
figure 2.1 Does
the START key
work.
Plug in Cin figure
2.1. Press
START
then the LEFT
STOP/RESET.
Does this work?
Replace lower
membrane
switch 833-132
Replace
STOP/
RESET
with 833-124
Plug in Din figure
2.1. Press
START
then the RIGHT
STOP/RESET.
Does this work?
Replace
STOP/
RESET
with 833-124
Plug in Ain figure
2.1. Press
START
then the resistance
HIGHER and
LOWER keys.
Does this work?
Replace
upper
keypad with
833-122

5
Electronic connections and LED locations
J1- located on Polar® wireless heart rate board
J8- wire plugs from J1 on Polar® wireless heart rate board
J5 R. Stop Switch- plug for the right stop switch located on the front of the upper console
J4 Handgrip- plug for wire coming from the Polar® contact heart rate board (only on contact HR models)
J6 to power supply- 8 pin telco communication wire plug from P1 on power supply board
J7 to power supply- 6 pin telco communication wire plug fromP2 on power supply board
J2 Kill Switch- used only on some treadmill models for the emergency stop tether
J12 Lower panel switch- plug for the lower membrane switch on the front of the upper console
J13 Upper Panel Switch- plug for the upper membrane switch on the front of the upper console
J11 L. Stop Switch- plug for the left stop switch located on the front of the upper console
D27 BRK OUT- Will be lit when resistance is selected on the upper console. Light will be dim at low resistance then gradually get
brighter as more resistance is selected.
D31 BRK IN- Will be lit when resistance is selected on the upper console.
D29 XMIT- This LED indicates that the PSB is sending information to the upper console, should be flashing.
D30 RCV- This LED indicates that the upper console is sending information to the PSB, should be flashing.
JP3 WPACK- This is a plug for the optional CS3 wall pack.
JP2 BATTERY- This is for the 12V battery.
D15 DC BUS- This LED indicates that it is receiving power from the generator.
JP1 GENERATOR- This is a 3 pin plug that goes directly to the generator, supplies power to the PSB and allows RPM to show on
the upper console.
JP5 BRAKE- This is a 2 pin plug that goes to the magnetic coil for breaking (resistance.)
P1 8 pin telco communication wire- Supplies both power and communication to the upper console.
P2 6 pin telco communication wire- Supplies both power and communication to the upper console.
D27 BRK OUT D31 BRK IN D29 XMIT D30 RCV
JP5 BRAKE
JP3 WPACK
JP2 BATTERY
D15 DC BUS
P2 6 pin telco communication wire
P1 8 pin telco communication wire
JP1 GENERATOR
J8 Polar reciever
J10 PC port
J1 C-safe
3pin HR wire 40"
3pin HR
wire 40"
J1 to upper
console
J5 R. Stop Switch J6 to power supply J7 to power supply J13 upper panel switch
8 pin telco 41" 6 pin telco 41" J12 lower panel switch J11 L. Stop Switch

6
ITEM NO.
QTY.
A
1
B
1
C
1
D
1
E
1
F
1
G
1
H
1
I
1
J
1
K
1
L
1
M
2
N
1
L
D
N
M
F
E
C
G
I
H
I
H
J
F
K
A
B
G
All Electronics Part Numbers
833-132 Lower membrane switch (Quickstart w/ numbers)
833-122 Upper overlay/ membrane switch
833-124 STOP membrane switch
149-121 UB300 2 pin brake wire- 11"
149-122 UB300 3 pin brake wire- 11"
149-119 UB300 telco communication wire, 6 pin- 41"
149-120 UB300 telco communication wire, 8 pin- 41"
149-117 UB300 battery wire- 14"
149-118 UB300 3 pin Polar® board wire- 44"
833-339 Generator brake, direct drive ROHS
833-106 12V 1.2Ah lead acid battery
833-429 Power supply board (version H15)
833-432 Single color upper console
PART NUMBER DESCRIPTION
833-280 Polar® wireless HR reciever board

7
ITEM NO.
QTY.
A
6
B
2
C
4
D
4
E
4
F
2
G
4
H
8
I
4
J
6
K
1
L
2
M
1
N
1
O
1
P
1
Q
1
R
1
S
1
T
2
U
1
E D
J G
,H,I
B J
J
D E
A
H
C
F
A
H
C A
S
R
Q
T
L
K
U
N
O,P
LOCATED INSIDE
HOUSING
M
PART NUMBER DESCRIPTION
833-508 Cardio seat wheel w/ bearing
750-023 cam tensioner
833-150 Seat pad (set)
810-971 shoulder bolt 3/8 x 1 1/2"
817-405 5/16" tall lock nut
818-004 1/4" zinc washer
810-965 shoulder bolt 3/8 x 3/4"
817-406 3/8" tall lock nut
819-012 3/8" machine bushing
819-707 3/8" external tooth lock washer
852-807 spring (cut in half)
858-321 grip 1.25"ID x 7" long
640-002 spring pin assembly w/ gold knob
spring 11/16" OD x 5" long
501-684 small diamond plate
852-207 gold knob
839-119 spring pin
Seat assembly Part Numbers
833-104 aluminum seat track extrusion
839-067 chrome seat adjustment plate
501-811 large diamond plate
854-056 number decal
852-801

8
ITEM NO.
QTY.
A
1
B
1
C
1
D
2
E
1
F
1
G
9
H
10
I
1
J
2
A
B
F
E
H
C
D
I
J
External component part numbers
833-114 3/8-16 leveling foot
833-127 1/4" black plastic rivet
009-642 moving wheel kit (2 wheels and hardware)
101-535 pivoting console frame
810-089 #6 x 3/4" black zinc screw
854-038 UBE decal
101-536 console support arm
833-259 ABS trim ring
833-089 smoke gray UBE guard set
PART NUMBER DESCRIPTION
500-001 steel console back plate

9
A
B
C
D
E
F
D
G
H
I
J
ITEM NO.
QTY.
A
1
B
1
C
1
D
2
E
1
F
1
G
1
H
1
I
1
J
1
K
1
L
1
M
1
N
1
O
1
P
1
12V 1.2Ah lead acid battery
belt tenisioner w/o pulley
2.91" convex belt ilder pulley w/ bushing
650J8 ribbed belt
2.35" sided flat belt idler pulley w/ bushing
DESCRIPTION
User crank pulley
3.24" sided flat belt idler pulley w/ bushing
See tranny diagrams 1-3
702-129
833-339
PART NUMBER
101-652
833-443
n/a
833-527
833-440
Head assembly part numbers
833-085 complete cable assembly
833-062 600N dual orifice shock
285J8 ribbed belt
generator brake, direct drive ROHS
702-131
833-442
833-106
833-086 release lever
833-087 jam nut
858-321 hand grip
817-020 10-32 x 1 1/4" phillips pan head bolt
K
L
M
N
O
P

10
ITEM NO.
QTY.
A
2
B
2
C
2
D
2
E
1
F
1
G
4
H
4
I
2
J
2
K
2
L
2
M
2
N
2
O
2
P
1
Q
1
R
2
S
2
A B
J,K
L
E
F
C
I
M
G
D
H
N
O
P
H
R
Q
S
Handle part numbers, fixed and optional adjustable (H option)
PART NUMBER DESCRIPTION
200-499 5/8" indented shaft
200-561 5/8" shaft, drilled one end 1/4-20
852-610 5/8" set collar
200-472 aluminum handle bearing end
200-471 aluminum key toward handle
200-634 aluminum handle away from handle
815-504 set screw 3/8-16 x 5/16"
851-632 1/2" ID flange bearing
854-968 number decal
818-004 1/4" zinc washer
813-402 1/4-20 x 1/2" zinc button head bolt
833-515 3/8-16 star knob
200-502 star knob spring housing
833-513 spring
200-501 adjustable handle plunger
101-683 fixed handle key away from handle
101-684 fixed handle key toward handle
833-149 plastisol dipped handle
858-320 grip for handle

11
Tranny parts diagram 1
15
9
11
12
13
16
9
7
3
11
45
17 68
9
14
13
12 18
10
9
17
11
13
11
17
2
12 13
12
8
11
11
12
20
20
19
I
T
E
M
N
O
.
Q
T
Y
.
P
A
R
T
N
U
M
B
E
R
D
E
S
C
R
I
P
T
I
O
N
1 1 501-682 3/8" PLASMA
2 2 833-026 20 FLANGE PILLOW BLOCK BEARING (REVERSED)
3 2 851-155 3/4" FLANGE PILLOW BLOCK BEARING (REVERSED)
4 1 851-156 LOCKING COLLAR
5 1 101-385 PULLEY
6 1 200-545 3/4"OD TGP - 5 3/8"
7 1 833-161 3/4" GEAR HUB ASSEMBLY
8 3 819-016 1 1/4"OD x 3/4"ID MACHINE BUSHING
9 4 819-315 3/4" EXTERNAL SNAP RING
10 1 200-538 20 HARDENED SHAFT - 7 1/16"
11 20 819-020 32 OD x 20.2 ID MACHINE BUSHING
12 8 833-028 20 THRUST WASHER
13 4 833-027 20 THRUST ROLLER BEARING
14 1 102-801 PULLEY WITH CLUTCH BEARING
15 2 833-507 3/4" SPRING WASHER
16 1 833-160 20 GEAR HUB ASSEMBLY
17 3 833-070 1/4" x 1/4" x 3/4" KEY
18 1 102-804 20 PULLEY
19 2 815-500 5/16" SET SCREW - 5/16"
20 4 815-508 5/16" SET SCREW - 3/4"

12
Tranny parts diagram 2
A
11
3
2
4
5
17
689
12
13 14
11
12
13
11
9
17
10
18
20
20
DETAIL A
TEXT ON CLUTCH BEARING
MUST FACE INSIDE

13
Tranny parts diagram 3
B
9
11
12
16 12
13
13
11
15
11
9
8
7
3
2
19
19
DETAIL B
TEXT ON CLUTCH BEARING
MUST FACE OUTSIDE